Allen-Bradley PowerFlex DC Hardware Service Manual
  1. Manuals
  2. Brands
  3. Allen-Bradley Manuals
  4. Controller
  5. PowerFlex DC
  6. Hardware service manual

Allen-Bradley PowerFlex DC Hardware Service Manual

Field controller, frame a and b
Hide thumbs
Table of Contents

Quick Links

Hardware Service Manual
Original Instructions
PowerFlex DC Field Controller, Frame A and B
Catalog Number 23PFC
Table of Contents
loading

Related Manuals for Allen-Bradley PowerFlex DC

Summary of Contents for Allen-Bradley PowerFlex DC

  • Page 1 Hardware Service Manual Original Instructions PowerFlex DC Field Controller, Frame A and B Catalog Number 23PFC...
  • Page 2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

  • Page 3: Table Of Contents

    Table of Contents Preface Additional Resources ......... . . 7 Chapter 1 Before You Begin Testing, General Safety Precautions .
  • Page 4 Table of Contents Communication Adapter and Electromagnetic Interference Shield Replacement ......... . . 38 Remove the Communication Adapter and Electromagnetic Interference Shield.
  • Page 5 Table of Contents Chapter 4 Frame B Field Controller Part Replacement Parts Kits ........78 Remove Power from the Device .
  • Page 6 Table of Contents SCR Modules Replacement ........103 Remove the SCR Modules .

  • Page 7: Preface

    It is highly recommended that you obtain a copy of the PowerFlex DC Field Controller Programming Manual, publication 23PFC-PM001. The PowerFlex DC Field Controller Programming Manual contains fault/alarm and programming information to assist you in troubleshooting device errors and determine if repairs are necessary.
  • Page 8 Preface Notes: Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 9 Chapter Before You Begin Testing, Maintenance or Repairs Topic Page General Safety Precautions Hardware Description Commonly Used Tools This chapter provides information to help you prepare for tests, maintenance, or repairs on device components. Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 10: General Safety Precautions

    Chapter 1 Before You Begin Testing, Maintenance or Repairs General Safety Precautions Read the following precautions before you test components, perform maintenance, or repair the device. ATTENTION: Only qualified personnel familiar with DC drives, field controllers, and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system.

  • Page 11: Hardware Description

    Verify the frame size of the field controller you are working on by checking the data nameplate that is on the side of the device. The frame size is printed just above the serial number in the lower right corner of the label. Frame A PowerFlex DC Field Controller Shown LISTED IND. CONT.

  • Page 12: Commonly Used Tools

    Chapter 1 Before You Begin Testing, Maintenance or Repairs Commonly Used Tools Service Tools This list includes the tools that are needed for installation and test measurements. Item Details Digital multimeter Digital multimeter, capable of AC and DC voltage, continuity, resistance and forward diode bias tests.
  • Page 13 Chapter Component Test Procedures Topic Page Save the Parameter Configuration Visual Component Inspection Troubleshoot a Control Power Supply Failure Troubleshoot an AC Undervoltage Fault Power Component Test Procedures Thermistors and Thermal Switches Relay Outputs Create a Fault Report What You Need When You Call Tech Support This chapter provides general procedures for inspecting and testing the major components of the field controller and includes recommendations for repairs.

  • Page 14: Save The Parameter Configuration

    Chapter 2 Component Test Procedures Save the Parameter It is recommended that you save the field controller and communication adapter parameter configuration before performing any service. You can save Configuration the device configuration by using one of these methods: • HIM Set - see Save to a HIM Set. •...

  • Page 15: Visual Component Inspection

    • For frame B devices, see page 3. If installed, remove the fiber-optic interface option module. See the PowerFlex DC Fiber-optic Interface Option Module Installation Instructions, publication 20P-IN078, for instructions. 4. Measure the signal voltage at the control circuit board testpoints as indicated in the following table.

  • Page 16: Test The Switching Power Supply And Pulse Transformer

    Chapter 2 Component Test Procedures Table 1 - Control Circuit Board Testpoints Name Testpoint For Testpoint Location Associated Connector- Description GNDV Figure 1 on page XA-15 +24V terminal block ground +5VEXP +5VEXP Figure 2 on page XP3-1 / XP3-2 / XP3-3 +5V for DPI expansion +12VEXP +12VEXP...

  • Page 17: Boards

    Component Test Procedures Chapter 2 Test the Switching Power Supply and Pulse Transformer Boards Complete these steps to test the switching power supply and pulse transformer circuit boards. 1. Replace the fuse/fuses on the switching power supply board. • For frame A devices, see page •...
  • Page 18 Chapter 2 Component Test Procedures Figure 1 - Control Board Testpoints - Upper Left XY18 XY17 XY19 XY10 XY12 XY11 XY6 XY5 XY20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DEBUG 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40...
  • Page 19 Component Test Procedures Chapter 2 Figure 2 - Control Board Testpoints - Upper Right +12VEXP 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DEBUG 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 - A B C + ENC_5 ENC_12...

  • Page 20: Troubleshoot An Ac Undervoltage Fault

    Chapter 2 Component Test Procedures Troubleshoot an AC Measure the AC line input signals, as directed in these steps, when one of these conditions exists: Undervoltage Fault • The device faults with an AC Undervoltage Fault (F4) • Parameter 466 [AC Line Voltage] does not equal the expected incoming AC line voltage ATTENTION: Servicing energized equipment can be hazardous.
  • Page 21 Component Test Procedures Chapter 2 • If any of the voltage measurements are incorrect or missing, continue with step 6. • If the voltage measurements are correct but the value of parameter 466 [AC Line Voltage] is incorrect, replace the control board. 6.

  • Page 22: Power Component Test Procedures

    Follow the applicable procedure for the affected power components. Procedures Check the SCR Modules The PowerFlex DC field controller power bridge consists of six SCR modules that are mounted on the main heat sink. One of these conditions can indicate a malfunction of a SCR module: •...
  • Page 23 Component Test Procedures Chapter 2 Figure 3 - Frame A SCR Module Layout SCR Modules Figure 4 - Frame B SCR Module Layout SCR Modules Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 24 Chapter 2 Component Test Procedures 6. Check the gate to cathode junction of each SCR. With a digital multimeter set to Ohms, measure the resistance of each SCR junction. • For frame A devices, see Table 4 Figure • For frame B devices, see Table 4 Figure 6 on page 25.

  • Page 25: Check The Pulse Transformer Board

    Component Test Procedures Chapter 2 Figure 6 - Frame B SCR Module Gate-Lead Connection Pinouts Gate Lead Pinouts Gate Lead Pinouts Check the Pulse Transformer Board The pulse transformer circuit board contains an isolated gate firing circuit and also provides dv/dt protection for the SCR modules. One of these conditions can indicate a malfunction of these devices: •...
  • Page 26 Chapter 2 Component Test Procedures 5. For 60 A frame A devices only, complete these steps: a. Remove the four screws that secure the slotted air flow plate to the top of the device. b. Remove the fan cable from connector XV on the switching power supply board and remove the plate.
  • Page 27 Component Test Procedures Chapter 2 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 7. Remove the pulse transformer board. The switching power supply board is mounted on the back of the pulse transformer board but does not need to be removed from the pulse transformer board for this test.

  • Page 28: Thermistors And Thermal Switches

    A “PTC Over Temp” fault (F16) or alarm typically signal that the load is overheating. • See Alarm Descriptions in the PowerFlex DC Field Controller Programming Manual, publication 23PFC-PM001, for details. • For frame A devices, see Figure 11 on page for a circuit diagram.

  • Page 29: Relay Outputs

    35 and 36 is configured with parameter 1392 [Relay Out 1 Sel]. The relay output between terminals 75 and 76 is configured with parameter 629 [Relay Out 2 Sel]. • See AC Input Contactors in the PowerFlex DC Field Controller Installation Instructions, publication 23PFC-PM001, for more information.
  • Page 30 Chapter 2 Component Test Procedures Table 7 to record the data that is provided in each PowerFlex DC field controller parameter listed. Table 7 - PowerFlex DC Field Controller Parameter Data Parameter Name Description Parameter Data 1349 Status1 at Fault Captures and displays Par 381 [Device Status 1] bit pattern at the time of the last fault.
  • Page 31 Chapter Frame A Field Controller Part Replacement Procedures Topic Page Replacement Part Kits Remove Power from the Device Switching Power Supply Fuse Replacement DPI / HIM Assembly Replacement Protective Cover Replacement Communication Adapter and Electromagnetic Interference Shield Replacement I/O Expansion Circuit Board Replacement 115V AC to 24V DC I/O Converter Circuit Board Replacement Control Circuit Board Replacement Control EMI Shield and Control Circuit Board Replacement...

  • Page 32: Replacement Part Kits

    Chapter 3 Frame A Field Controller Part Replacement Procedures Replacement Part Kits Table 8 lists the spare parts kits available for PowerFlex® DC frame A field controllers. Table 8 - Frame A Field Controller Spare Part Kits Description Kit Cat. No. Instructions Page Fuses...

  • Page 33: Remove Power From The Device

    Frame A Field Controller Part Replacement Procedures Chapter 3 Remove Power from the Device ATTENTION: Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc can occur. An electrical arc can cause personal injury or equipment damage by: •...

  • Page 34: Switching Power Supply Fuse Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures Switching Power Supply Fuse Remove the Fuse on the Switching Power Supply Circuit Board Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 33). 3.

  • Page 35: Dpi / Him Assembly Replacement

    Frame A Field Controller Part Replacement Procedures Chapter 3 DPI / HIM Assembly Remove the DPI / HIM Assembly from the Protective Cover Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 33). 3.

  • Page 36: Protective Cover Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures Protective Cover Remove the Protective Covers Replacement You must remove both the lower protective cover and the power terminal cover to access the power terminals. 1. Read the General Safety Precautions on page 10. 2.
  • Page 37 Frame A Field Controller Part Replacement Procedures Chapter 3 4. Disconnect the DPI cable from the HIM assembly. 5. Loosen the two screws that secure the bottom protective cover to the device. 6. While lifting along the top edge of the cover, slide it down and off the device chassis.

  • Page 38: Install The Protective Covers

    Chapter 3 Frame A Field Controller Part Replacement Procedures 9. Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside. Install the Protective Covers Install the protective covers in reverse order of removal. ATTENTION: Risk of electric shock exists when power is applied to the power terminals of the device.
  • Page 39 Frame A Field Controller Part Replacement Procedures Chapter 3 4. Disconnect the interface cable from the communication adapter and set it aside. 5. Disconnect any network cables from the adapter and set them aside. 6. Remove the four screws that secure the communication adapter to the Electromagnetic Interference (EMI) shield and remove the adapter.

  • Page 40: Install The Communication Adapter And Electromagnetic

    Chapter 3 Frame A Field Controller Part Replacement Procedures 7. Remove the three screws that secure the EMI shield to the stand-offs on the control board and remove the EMI shield. Torque Specification: 1.0 N•m (8.9 lb•in) 8. Remove the three stand-offs from the control board. Torque Specification: 1.0 N•m (8.9 lb•in) Install the Communication Adapter and Electromagnetic...

  • Page 41: I/O Expansion Circuit Board Replacement

    Frame A Field Controller Part Replacement Procedures Chapter 3 I/O Expansion Circuit Board Remove the I/O Expansion Circuit Board Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 33). 3. Remove the protective covers (see page 36). IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly.
  • Page 42 Chapter 3 Frame A Field Controller Part Replacement Procedures 7. Remove the two stand-offs from the control board. Torque Specification: 1.0 N•m (8.9 lb•in) 8. Install one of the existing screws in the lower left corner of the control circuit board. Torque Specification: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 43: Install The I/O Expansion Circuit Board

    Frame A Field Controller Part Replacement Procedures Chapter 3 Install the I/O Expansion Circuit Board Install the I/O expansion board in reverse order of removal. 115V AC to 24V DC I/O Remove the 115V AC to 24V DC I/O Converter Circuit Board Converter Circuit Board 1.

  • Page 44: Install The 115V Ac To 24V Dc I/O Converter

    Chapter 3 Frame A Field Controller Part Replacement Procedures 6. Remove the two stand-offs from the control board. Torque Specification: 1.0 N•m (8.9 lb•in) Install the 115V AC to 24V DC I/O Converter Circuit Board Install the 115V AC to 24V DC I/O converter board in reverse order of removal.
  • Page 45 7. If installed, remove the 115V AC to 24V DC I/O converter circuit board (see page 43). 8. Record all switch and jumper settings on the control board. See the PowerFlex DC Field Controller Installation Instructions, publication 23PFC-IN001, for more information. Jumper/...
  • Page 46 Chapter 3 Frame A Field Controller Part Replacement Procedures 9. Carefully disconnect the cables from connectors XA and XR on the control board. 10. Remove the plug-in I/O and control terminal blocks with the wiring kept in place. Control board shown with communication adapter and optional boards removed.

  • Page 47: Install The Control Circuit Board

    Frame A Field Controller Part Replacement Procedures Chapter 3 11. Remove the five M3 x 6 mm screws and washers that secure the control board to the control EMI shield and remove the control board. Torque Specification: 1.0 N•m (8.9 lb•in) Install the Control Circuit Board Install the control board in reverse order of removal.

  • Page 48: Control Emi Shield And Control Circuit Board Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures Control EMI Shield and Remove the Control EMI Shield and Control Circuit Board Control Circuit Board You must remove the control EMI shield that holds the control board to access Replacement other components within the device.

  • Page 49: Install The Control Emi Shield And Control Circuit Board

    Frame A Field Controller Part Replacement Procedures Chapter 3 6. Remove the five M4 x 9.5 mm screws that secure the control EMI shield and ground wire (in the lower left corner) to the chassis. Slide the control EMI shield and control board up and out of the device. IMPORTANT Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the pulse transformer circuit board below the EMI shield.

  • Page 50: Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures Pulse Transformer and Remove the Pulse Transformer and Switching Power Supply Circuit Switching Power Supply Board Circuit Board Replacement The switching power supply circuit board is on the back of the pulse transformer circuit board.
  • Page 51 Frame A Field Controller Part Replacement Procedures Chapter 3 6. For 17 A field controllers, remove the two screws that secure the slotted air flow plate to the top of the device and remove the plate. Torque Specification: 1.0 N•m (8.9 lb•in) Air flow plate Torque Specification: 1.0 N•m (8.9 lb•in)
  • Page 52 Chapter 3 Frame A Field Controller Part Replacement Procedures 8. Remove the cables from connectors X3 and X4 at the top of the pulse transformer board. For devices without a fan, do not remove the jumper in connector X4. 9. Remove the plastic screw near the top of the pulse transformer board and retain for reuse.
  • Page 53 Frame A Field Controller Part Replacement Procedures Chapter 3 10. Remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and KG1…KG6 and push each lead through the appropriate opening in the board. IMPORTANT Carefully remove the gate leads by grasping the connector. DO NOT pull the gate leads off by pulling on the wires.
  • Page 54 Chapter 3 Frame A Field Controller Part Replacement Procedures 12. Remove the six M3 x 6 mm screws and washers that secure the bottom of the pulse transformer board to the chassis. While lifting slightly on the board, slide it toward the top of the device and out of the chassis. There is an isolation sheet below the board;...
  • Page 55 Frame A Field Controller Part Replacement Procedures Chapter 3 13. Remove the cable from connector XUV on the left side of the switching power supply board. 14. Remove the four M3 x 6 mm screws and washers that secure the switching power supply board to the stand-offs on the back of the pulse transformer board.

  • Page 56: Install The Pulse Transformer And Switching Power Supply

    Chapter 3 Frame A Field Controller Part Replacement Procedures Install the Pulse Transformer and Switching Power Supply Circuit Boards Before you install a new pulse transformer circuit board, you must configure the DIP switches on the circuit board to match the field controller size (output current rating).
  • Page 57 Frame A Field Controller Part Replacement Procedures Chapter 3 IMPORTANT A blank cell below a switch in Table 9 indicates that the setting is “OFF”. Table 9 - DIP Switch S3 and S4 Settings - FIR1-xx-FC Device Output DIP Switch S3 DIP Switch S4 Current (Amps) S3-1...

  • Page 58: Ac Current Transducer Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures AC Current Transducer Remove the AC Current Transducers Replacement IMPORTANT AC current transducers must be replaced in pairs. 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 33). 3.
  • Page 59 Frame A Field Controller Part Replacement Procedures Chapter 3 Remove the Current Transducers with Connection Bars 6. Remove the four M3 x 6 mm screws and washers that secure the top of the AC current transducers to the power traces board. 7.
  • Page 60 Chapter 3 Frame A Field Controller Part Replacement Procedures 8. Turn the board over and remove the two M3 x 6 mm screws and washers that secure the AC current transducers to the board. Remove the AC current transducers and windings (if present) from the device. IMPORTANT You do not need to remove the windings from the AC current transducers.
  • Page 61 Frame A Field Controller Part Replacement Procedures Chapter 3 12. Remove the two 5 x 10 mm screws and washers that secure each of the U and V phase terminal bus bars to the terminal isolation strip at the bottom of the device. Torque Specification: U phase bus bar V phase bus bar...

  • Page 62: Install The Ac Current Transducers

    Chapter 3 Frame A Field Controller Part Replacement Procedures Install the AC Current Transducers Install the AC current transducers in reverse order of removal. For AC current transducers that must be wound with wire leads: • Wind the wire leads around the new AC current transducers the exact number of times and in the same position as the wires on the AC current transducers that were removed from the power traces board.

  • Page 63: Power Traces Circuit Board Replacement

    Frame A Field Controller Part Replacement Procedures Chapter 3 Power Traces Circuit Board Remove the Power Traces Circuit Board Replacement The power traces circuit board is only contained in 17 A and 60 A frame A field controllers. 1. Read the General Safety Precautions on page 10. 2.
  • Page 64 Chapter 3 Frame A Field Controller Part Replacement Procedures 7. Remove the six stand-offs (and the ground wire) from the power traces circuit board. 8. Remove all M5 x 10 mm screws and washers that secure the board to the SCR modules and power terminal isolation strip.

  • Page 65: Install The Power Traces Circuit Board

    Frame A Field Controller Part Replacement Procedures Chapter 3 10. For devices with AC current transducers with no connection bars, turn the board over and remove the two screws and washers that secure the AC current transducers to the board. Remove the AC current transducers and windings (if present) from the device.

  • Page 66: Bimetal Thermostat Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures Bimetal Thermostat Remove the Bimetal Thermostat Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 33). 3. Remove the protective covers (see page 36). 4.

  • Page 67: Scr Module Replacement

    Frame A Field Controller Part Replacement Procedures Chapter 3 SCR Module Replacement Remove the SCR Modules IMPORTANT The SCR modules must be replaced in pairs for each input phase in order that the gating resistance of each pair of modules is the same. 1.

  • Page 68: Torque Specification: 2.5 N•M (22.0 Lb•In)

    Chapter 3 Frame A Field Controller Part Replacement Procedures SCR Modules on 120 A Field Controllers 6. Remove the isolation sheet. 7. Remove the M5 x 10 mm screws that secure the U, V, W, C, and D terminal bus bars to the power terminal isolation strip at the bottom of the device.
  • Page 69 Frame A Field Controller Part Replacement Procedures Chapter 3 8. Remove the screws and washers that secure the connecting bus bars to the anodes of the corresponding SCR modules and remove the bus bars. In addition, remove the U, V, and W phase terminal bus bars from the device.
  • Page 70 Chapter 3 Frame A Field Controller Part Replacement Procedures 9. Remove the four M5 x 16 screws and washers that secure the C and D terminal bus bars to the horizontal bus bars. Remove the C and D terminal bus bars. 10.

  • Page 71: Install The Scr Modules

    Frame A Field Controller Part Replacement Procedures Chapter 3 11. Remove the screws and washers that secure each SCR module to the heat sink and remove the SCR modules. Install the SCR Modules IMPORTANT Thermal grease must be applied to the bottom of each SCR module before securing it to the heat sink.

  • Page 72: Cooling Fan Replacement

    Chapter 3 Frame A Field Controller Part Replacement Procedures • Use the following table to determine the proper tightening torque for the bus bars to SCR modules connections. Device Output Rockwell Automation Vendor Vendor Part Number Final Torque Current (Amps) Cat.
  • Page 73 Frame A Field Controller Part Replacement Procedures Chapter 3 Cooling Fan on 60 Amp Field Controllers 60 Amp frame A field controllers have a cooling fan that is installed at the top of the device. 3. Remove the four screws that secure the slotted air flow plate and fan to the top of the chassis.
  • Page 74 Chapter 3 Frame A Field Controller Part Replacement Procedures Cooling Fan on 120 Amp Field Controllers 120 Amp Frame A field controllers have a cooling fan that is installed on the bottom of the device. 3. Loosen the two screws that secure the power terminal cover to the device and slide the cover down and off the chassis.
  • Page 75 Frame A Field Controller Part Replacement Procedures Chapter 3 5. Remove the six M4 x 12.5 mm screws that secure the air flow plate to the bottom of the device chassis. Carefully pull the air flow plate and fan assembly down and off the device. IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly.

  • Page 76: Install The Cooling Fan

    Chapter 3 Frame A Field Controller Part Replacement Procedures 7. Using a flathead screwdriver, pry the fan cover plate off the air flow plate and slide the fan out of the air flow housing. Install the Cooling Fan Install the cooling fan in reverse order of removal. IMPORTANT For both fan configurations, verify that the air flow arrow on the fan is pointed toward the top of the device.

  • Page 77: Rockwell Automation Publication 23Pfc-Tg001A-En-P - March

    Chapter Frame B Field Controller Part Replacement Procedures Topic Page Remove Power from the Device DPI / HIM Assembly Replacement Protective Cover Replacement Communication Adapter and Electromagnetic Interference Shield Replacement I/O Expansion Circuit Board Replacement 115V AC to 24V DC I/O Converter Circuit Board Replacement Control Circuit Board Replacement Control Electromagnetic Interference Shield Removal and Closure Switching Power Supply Board Fuse Replacement...

  • Page 78: Frame B Field Controller Part Replacement Procedures

    Chapter 4 Frame B Field Controller Part Replacement Procedures Replacement Parts Kits Table 10 lists the spare parts kits available for PowerFlex® DC frame B field controllers. Table 10 - Frame B Field Controller Spare Part Kits Description Kit Cat. No. Instructions Page Fuses/Fuse Holders...

  • Page 79: Remove Power From The Device

    Frame B Field Controller Part Replacement Procedures Chapter 4 Remove Power from the Device ATTENTION: Remove power before you make or break cable connections. When you remove or insert a cable connector with power applied, an electrical arc can occur. An electrical arc can cause personal injury or property damage by: •...

  • Page 80: Install The Dpi / Him Assembly

    Chapter 4 Frame B Field Controller Part Replacement Procedures 4. Remove the screw that secures the DPI / HIM assembly to the device. 5. Carefully remove the DPI / HIM assembly from the cover and disconnect the cable from the DPI connector on the back side of the assembly.
  • Page 81 Frame B Field Controller Part Replacement Procedures Chapter 4 3. Disconnect the DPI cable from the HIM assembly. 4. Loosen, but do not remove, the screws that secure the bottom cover to the device, then slide the cover down and off the device chassis. Torque Specification: 1.5 N m (13.3 lb...

  • Page 82: Install The Protective Covers

    Chapter 4 Frame B Field Controller Part Replacement Procedures 6. Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside. Install the Protective Covers Install the protective covers in the reverse order of removal. ATTENTION: Risk of electric shock exists when power is applied to the power terminals of the device.

  • Page 83: Communication Adapter And Electromagnetic Interference Shield Replacement

    Frame B Field Controller Part Replacement Procedures Chapter 4 Communication Adapter and Remove the Communication Adapter and Electromagnetic Electromagnetic Interference Shield Interference Shield 1. Read the General Safety Precautions on page 10. Replacement 2. Remove power from the device (see page 79). 3.

  • Page 84: Install The Communication Adapter And Electromagnetic

    Chapter 4 Frame B Field Controller Part Replacement Procedures 7. Remove the three screws that secure the EMI shield to the standoffs on the control board and remove the EMI shield. Torque Specification: 1.0 N m (8.9 lb • • 8.

  • Page 85: I/O Expansion Circuit Board Replacement

    Frame B Field Controller Part Replacement Procedures Chapter 4 I/O Expansion Circuit Board Remove the I/O Expansion Circuit Board Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 79). 3. Remove the protective covers from the device (see page 80). IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly.

  • Page 86: Install The I/O Expansion Circuit Board

    Chapter 4 Frame B Field Controller Part Replacement Procedures 7. Remove the two stand-offs from the control board. Torque Specification: 1.0 N•m (8.9 lb•in) 8. Install one screw in the lower left corner of the control board. Torque Specification: 1.0 N•m (8.9 lb•in) Install the I/O Expansion Circuit Board Install the I/O expansion board in reverse order of removal.

  • Page 87: Ac To 24V Dc I/O Converter Circuit Board Replacement

    Frame B Field Controller Part Replacement Procedures Chapter 4 115V AC to 24V DC I/O Remove the 115V AC to 24V DC I/O Converter Circuit Board Converter Circuit Board 1. Read the General Safety Precautions on page 10. Replacement 2. Remove power from the device (see page 79). 3.

  • Page 88: Install The 115V Ac To 24V Dc I/O Converter

    Chapter 4 Frame B Field Controller Part Replacement Procedures Install the 115V AC to 24V DC I/O Converter Circuit Board Install the 115V AC to 24V DC I/O converter board in reverse order of removal. Control Circuit Board Remove the Control Circuit Board Replacement 1.
  • Page 89 Frame B Field Controller Part Replacement Procedures Chapter 4 8. Record all switch and jumper settings on the control board. See the PowerFlex DC Field Controller Installation Instructions, publication 23PFC-IN001, for more information. Jumper Function Setting /Switch Configures the input signal of analog input 1 (terminals 1 and 2): Par 71 [Anlg In1 Config] must be programmed to match the input signal type that is selected with this switch.

  • Page 90: Install The Control Circuit Board

    Chapter 4 Frame B Field Controller Part Replacement Procedures 11. Remove the five screws that secure the control board to the control EMI shield and remove the board. Torque Specification: 1.0 N•m (8.9 lb•in) Install the Control Circuit Board Install the control board in reverse order of removal. •...

  • Page 91: Close The Control Emi Shield In The Service Position

    Frame B Field Controller Part Replacement Procedures Chapter 4 4. Carefully disconnect the cables from connectors XA and XR on the control board. 5. Loosen the two captive screws at the top of the control EMI shield and lower shield. IMPORTANT If the device is not in a vertical position, the control EMI shield will not remain open without a means of restraint.

  • Page 92: Switching Power Supply Board Fuse Replacement

    Chapter 4 Frame B Field Controller Part Replacement Procedures Switching Power Supply Remove the Fuses on the Switching Power Supply Circuit Board Board Fuse Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 79). 3.

  • Page 93: Install The Fuses On The Pulse Transformer Circuit Board

    Frame B Field Controller Part Replacement Procedures Chapter 4 5. Using a fuse puller, carefully remove the three fuses from the fuse holders on the pulse transformer board. Install the Fuses on the Pulse Transformer Circuit Board Install the fuses on the pulse transformer circuit board in reverse order of removal.
  • Page 94 Chapter 4 Frame B Field Controller Part Replacement Procedures 4. Remove the four screws that secure the slotted air flow plate to the top of the device chassis. IMPORTANT The air flow plate is also secured to the pulse transformer circuit board and therefore cannot yet be removed.
  • Page 95 Frame B Field Controller Part Replacement Procedures Chapter 4 8. Remove the two screws that secure the air flow plate to the top of the pulse transformer board and lift the plate off the device chassis. 9. Remove the cable from connector XV on the switching power supply board.
  • Page 96 Chapter 4 Frame B Field Controller Part Replacement Procedures 10. Remove the cables from connector X4 on the pulse transformer board. 11. Remove the ground connection at the left side of the pulse transformer board. Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 97 Frame B Field Controller Part Replacement Procedures Chapter 4 12. Remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and KG1…KG6 and push each lead through the appropriate opening in the board. IMPORTANT Carefully remove the gate leads by grasping the connector. DO NOT pull the gate leads off by pulling on the wires.
  • Page 98 Chapter 4 Frame B Field Controller Part Replacement Procedures 14. Remove the cable from connector XUV on the switching power supply board. 15. Remove the six screws and washers that secure the switching power supply board to the stand-offs on the back of the pulse transformer board.

  • Page 99: Install The Pulse Transformer And Switching Power Supply

    Frame B Field Controller Part Replacement Procedures Chapter 4 Install the Pulse Transformer and Switching Power Supply Circuit Boards Before you install a new pulse transformer circuit board, you must configure the DIP switches on the circuit board to match the field controller size (output current rating).
  • Page 100 Chapter 4 Frame B Field Controller Part Replacement Procedures IMPORTANT A blank cell below a switch in Table 11 indicates that the setting is “OFF”. Table 11 - DIP Switch S3 and S4 Settings - FIR2-xx-FC Output DIP Switch S3 DIP Switch S4 Current S3-1...

  • Page 101: Ac Line Snubber Circuit Board And Resistors Replacement

    Frame B Field Controller Part Replacement Procedures Chapter 4 AC Line Snubber Circuit Board Remove the AC Line Snubber Circuit Board and Resistors and Resistors Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 79). 3.
  • Page 102 Chapter 4 Frame B Field Controller Part Replacement Procedures 7. Remove the three screws and washers that secure the AC line snubber board to the device frame and lift the board. Note: The wires from the resistors are connected to the board. Therefore, the board cannot be removed until the resistors are removed.

  • Page 103: Install The Ac Line Snubber Circuit Board And Resistors

    Frame B Field Controller Part Replacement Procedures Chapter 4 Install the AC Line Snubber Circuit Board and Resistors Install the AC line snubber board and resistors in reverse order of removal. IMPORTANT Thermal grease must be applied to the bottom of the resistors before securing them to the heat sink.
  • Page 104 Chapter 4 Frame B Field Controller Part Replacement Procedures 7. Remove the two screws or bolts and washers that secure the (red and blue) wires from the AC line snubber board to the terminal bus bars (C and D) and remove the wires. 8.
  • Page 105 Frame B Field Controller Part Replacement Procedures Chapter 4 9. Remove the three bolts that remain and washers that secure the AC input bus bars (U, V, and W phases) to the anode of the SCR modules and remove the bus bars. Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 106 Chapter 4 Frame B Field Controller Part Replacement Procedures 10. Remove the three pairs of upper gate leads from the SCR modules. 11. Remove the bolts and washers that secure the DC bus bars to the SCRs and remove the bus bars. 12.

  • Page 107: Install The Scr Modules

    Frame B Field Controller Part Replacement Procedures Chapter 4 13. Remove the two screws and washers that secure each SCR module to the heat sink and remove the SCR module. Install the SCR Modules Install the SCR modules in reverse order of removal. IMPORTANT Thermal grease must be applied to the bottom of each SCR module before securing it to the heat sink.
  • Page 108 Chapter 4 Frame B Field Controller Part Replacement Procedures • Use the following table to determine the proper tightening torque for the SCR modules that are installed on the heat sink. Device Output Rockwell Automation Vendor Vendor Part Number Final Torque Current (Amps) Cat.
  • Page 109 Frame B Field Controller Part Replacement Procedures Chapter 4 • The longer legs of the intermediate AC input bus bars connect to the top of the SCR modules: Top of Device Long Leg Intermediate SCR Module on Bus Bar Heat Sink Short Leg Phase U, V, or W Bus Bar...

  • Page 110: Ac Current Transducers Replacement

    Chapter 4 Frame B Field Controller Part Replacement Procedures AC Current Transducers Remove the AC Current Transducers Replacement 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 79). 3. Remove the screws and washers that secure the plastic shields to the bottom of the device and remove the shields.
  • Page 111 Frame B Field Controller Part Replacement Procedures Chapter 4 7. Remove the bolts and washers that secure the U and V phase AC input bus bars to the isolation bar. 8. Remove the bolts and washers that secure the resistor wires and the connecting bus bars to the U and V Phase SCR modules and remove the wires and bus bars.

  • Page 112: Install The Ac Current Transducers

    Chapter 4 Frame B Field Controller Part Replacement Procedures 9. Slide the U and V phase bus bars that pass through the AC current transducers up and out of the device. 10. Remove the screw and washer that secures each of the AC current transducers to the device frame and remove the AC current transducers.

  • Page 113: Bimetal Thermostats Replacement

    Frame B Field Controller Part Replacement Procedures Chapter 4 • Use the following table to determine the proper tightening torque for the bus bars connected to the SCR modules: Device Output Rockwell Automation Vendor Vendor Part Number Final Torque Current (Amps) Cat.
  • Page 114 Chapter 4 Frame B Field Controller Part Replacement Procedures 6. Remove the pulse transformer and switching power supply boards from the device (see page 93). You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure.
  • Page 115 Frame B Field Controller Part Replacement Procedures Chapter 4 9. Remove the bolt and washers that secure the D terminal bus bar to the terminal isolation bar. 10. Remove the screw and washer that secures the wire to the bus bar and the bolt and washer that secures the U phase bus bar to the SCR module and remove the bus bar.

  • Page 116: Install The Bimetal Thermostats

    Chapter 4 Frame B Field Controller Part Replacement Procedures 11. Remove the solder from the connections on the two leads of the bimetal thermostats. 12. Remove the bimetal thermostats from the heat sinks by unscrewing them at the base. 11 and 12 Install the Bimetal Thermostats Install the bimetal thermostats in reverse order of removal.

  • Page 117: Cooling Fan Replacement

    Frame B Field Controller Part Replacement Procedures Chapter 4 Cooling Fan Replacement Remove the Cooling Fans 1. Read the General Safety Precautions on page 10. 2. Remove power from the device (see page 79). 3. Remove the two screws that secure the rear plastic shield to the bottom of the device and remove the shield.

  • Page 118: Install The Cooling Fans

    Chapter 4 Frame B Field Controller Part Replacement Procedures 5. Using a flathead screwdriver, carefully pry the fan cover plate off the fan housing. 6. Remove the two screws that secure the fan to the device frame. You must insert a Phillips head screwdriver through the hole in the front of the fan housing to reach and remove the screws.

  • Page 119: Verify Field Controller Operation Connected To A Load

    Chapter Start-up after Repair Before you apply power to a repaired device, perform the following tests: • Check the SCR Modules on page • Complete the Verify Field Controller Operation Connected to a Load as detailed here. Verify Field Controller This procedure requires a HIM to configure and tune the device.
  • Page 120 Chapter 5 Start-up after Repair 8. Verify that the following parameter values are set correctly: • 175 [Load Rated Volt] is set to the load nominal (rated) voltage for the field controller. • 179 [Load Rated Curr] is set to the load nominal (rated) current. •...

  • Page 121: List Of Schematic Diagrams

    Appendix Schematics List of Schematic Diagrams Topic Page Frame A Field Controllers Frame A Field Controller Interconnection Diagram Frame A Power Feedback Connections Diagram Frame A SCR to Pulse Transformer Board Gate Lead Pinout Diagram Frame A Control Circuit Input Power Diagram Frame A Motor Thermal Protection Control Circuit Diagram Frame A Heat Sink Monitoring Control Circuit Diagram Frame B Field Controllers...

  • Page 122: Frame A Field Controllers

    Appendix A Schematics Frame A Field Controllers Figure 7 - Frame A Field Controller Interconnection Diagram Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 123 Schematics Appendix A Figure 8 - Frame A Power Feedback Connections Diagram Hardware connections to power structure bus bars. XR19 *Note XR18 *Note XR15 *Note XR16 *Note XR17 *Note *Note: 6 x 665 kohm resistors Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 124 Appendix A Schematics Figure 9 - Frame A SCR to Pulse Transformer Board Gate Lead Pinout Diagram SCR Module 1 SCR Module 01 SCR Module 2 SCR Module 02 SCR Module 3 SCR Module 03 G01 K01 K04 G04 G02 K02 K05 G05 G03 K03 K06 G06 6 6 7 7 4 4 5 5...
  • Page 125 Schematics Appendix A Figure 11 - Frame A Motor Thermal Protection Control Circuit Diagram +24V Overtemp Fault Signal Figure 12 - Frame A Heat Sink Monitoring Control Circuit Diagram Control Board XR-10 XR-10 XR-12 XR-12 X4-1 XSW-1 +24V X4-2 0V24 XSW-2 Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 126: Frame B Field Controllers

    Appendix A Schematics Frame B Field Controllers Figure 13 - Frame B Field Controller Interconnection Diagram Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 127 Schematics Appendix A Figure 14 - Frame B Power Feedback Connections Diagram XR15 XR16 XR17 XR19 XR18 Figure 15 - Frame B Control Circuit Input Power Diagram 230 VAC 115 VAC To Switch Input Mode Power Supply (SMPS) Figure 16 - Frame B Motor Thermal Protection Control Circuit Diagram +15V XR-32 Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 128 Appendix A Schematics Figure 17 - Frame B Heat Sink Monitoring Control Circuit Diagram Pulse Transformer Board Control Board XR-12 XR-12 XR-10 XR-10 +24V XSW-1 X4-1 X4-2 XSW-2 0V24 Figure 18 - Frame B AC Line Snubber Circuit Diagram 2W2 3W2 AC Line Snubber Board Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 129: Frame A And B Field Controllers

    Schematics Appendix A Frame A and B Field Figure 19 - Frame A and B AC Line Measurement Points Diagram Controllers XY22 XR-15 100 K +15 V -15 V XY21 XR-16 100 K XY18 XR-17 100 K Figure 20 - Frame A and B Contactor Control Relays Control Circuit Diagram 0V24 +24V Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 130 Appendix A Schematics Notes: Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 131: List Of Circuit Board Layouts

    Appendix Circuit Board Layouts and Connections List of Circuit Board Layouts The following images and tables detail the connection points for the frame A PowerFlex® DC field controller circuit boards and components. Topic Page Frame A Pulse Transformer Board Layout Pulse Transformer Board to Switching Power Supply Connections - Frame A Pulse Transformer Board to Bimetal Thermostat Connections - Frame A Pulse Transformer Board to Current Transducer Connections - Frame A...

  • Page 132: Frame A Pulse Transformer Board

    Appendix B Circuit Board Layouts and Connections Frame A Pulse Transformer Figure 21 - Frame A Pulse Transformer Board Layout Board XSW1 XI2CA 1C2 - 1D2 TR01 TR04 TR02 TR05 TR03 TR06 78 79 35 36 75 76 U2 V2 Control Power Terminal Block Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 133: Pulse Transformer Board To Switching Power Supply Connections - Frame A

    Circuit Board Layouts and Connections Appendix B Table 12 - Pulse Transformer Board to Switching Power Supply Connections - Frame A Pulse Transformer Switching Power Supply Description Board Point Number Board Connector … Rectified U2, V2 voltage (approx. 150/300V DC) …...

  • Page 134: Pulse Transformer Board To Control Board Connections - Frame A

    Appendix B Circuit Board Layouts and Connections Table 15 - Pulse Transformer Board to Control Board Connections - Frame A Pulse Control Board Description Transformer Number Number Connector Board Connector … 1 Gate signal G1 field SCR1 … 2 Gate signal G2 field SCR2 …...

  • Page 135: Frame A Switching Power Supply Board

    Circuit Board Layouts and Connections Appendix B Frame A Switching Power Figure 22 - Frame A Switching Power Supply Board Layout Supply Board Fuse location XSW1 Table 16 - Switching Power Supply to Fan Connections - Frame A Control Board Pin Number Pin Number Fan Connector...

  • Page 136: Switching Power Supply Board To Control Board Connections - Frame A

    Appendix B Circuit Board Layouts and Connections Table 17 - Switching Power Supply Board to Control Board Connections - Frame A Switching Pin Number Pin Number Control Board Description Power Supply Connector Board Connector … … 5V common … … 5V common …...

  • Page 137: Frame B Pulse Transformer Board

    Circuit Board Layouts and Connections Appendix B Frame B Pulse Transformer Figure 23 - Frame B Pulse Transformer Board Layout Board XI2CA 1U2 1V2 78 79 35 36 75 76 U2 V2 Control Power Terminal Block Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 138: Pulse Transformer Board To Switching Power Supply Connections - Frame B

    Appendix B Circuit Board Layouts and Connections Table 18 - Pulse Transformer Board to Switching Power Supply Connections - Frame B Pulse Transformer Pin Number Switching Power Supply Description Board Point Board Connector … 4 Rectified U2-V2 voltage (approx. 150/300V DC) …...

  • Page 139: Pulse Transformer Board To Control Board Connections - Frame B

    Circuit Board Layouts and Connections Appendix B Table 21 - Pulse Transformer Board to Control Board Connections - Frame B Pulse Transformer Control Board Description Board Connector Number Number Connector … Gate signal G1 field SCR1 … Gate signal G2 field SCR2 …...

  • Page 140: Frame B Switching Power Supply Board

    Appendix B Circuit Board Layouts and Connections Frame B Switching Power Figure 24 - Frame B Switching Power Supply Board Layout Supply Board SB SA Table 22 - Switching Power Supply Board to Control Board Connections - Frame B Switching Power Pin Number Pin Number Control Board...

  • Page 141: Control Board

    Circuit Board Layouts and Connections Appendix B Control Board Figure 25 - Control Board Layout To DPI board on HIM Bezel LA LB XFCD 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DEBUG 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40...
  • Page 142 Appendix B Circuit Board Layouts and Connections Notes: Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 143 Appendix Troubleshooting Flow Chart This chart presents the steps for troubleshooting a Power Failure fault (F3). See Troubleshoot a Control Power Supply Failure on page for the step-by-step instructions. Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...

  • Page 144: Control Power Supply Failure Flow Chart

    Appendix C Troubleshooting Flow Chart Control Power Supply Failure Flow Chart Measure the voltage at terminals U2, V2. Verify the wiring and Is the correct power source to U2, voltage present at V2 and correct any U2, V2? problems. Remove AC control power and remove and test the fuses F1 and F2 (if present) at...

  • Page 145: Index

    Index Numerics cooling fan (frame A) install 76 115V AC to 24V DC I/O converter board (frame remove 72 cooling fan (frame B) install 44 install 118 remove 43 remove 117 AC current transducer (frame A) DPI/HIM assembly (frame A) install 62 install 35 remove 58...

  • Page 146: Rockwell Automation Publication 23Pfc-Tg001A-En-P - March

    Index install power traces board (frame A) 115V AC to 24V DC I/O converter board install 65 (frame A) 44 remove 63 AC current transducer (frame A) 62 protective cover (frame A) AC current transducer (frame B) 112 install 38 AC line snubber board and resistor (frame B) remove 36 protective cover (frame B)
  • Page 147 Index safety precaution 10 save parameter configuration 14 schematic diagrams 121 SCR module test 22 SCR module (frame A) install 71 remove 67 SCR module (frame B) install 107 remove 103 service tool list 12 spare part list frame A 32 frame B 78 switching power supply board (frame A) fuse 34...
  • Page 148 Index Notes: Rockwell Automation Publication 23PFC-TG001A-EN-P - March 2018...
  • Page 150 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Connected Components Workbench, DriveExecutive, PowerFlex, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual is also suitable for:

23pfc

Table of Contents